Sub-frame and component configuration for mounting of a motorcycle drop seat

ABSTRACT

A sub-frame and component configuration for mounting on a motorcycle includes a body frame structure including a main frame portion; and a sub-frame portion, he sub-frame is fixedly secured to the main frame portion and is configured for receiving and securing thereon a drop seat providing a rider with a seating area that is relatively closer to the ground than the seating area of a conventional motorcycle seat. A method of mounting the sub-frame on a motorcycle includes: fixedly securing a drop seat sub-frame portion onto a main frame portion, wherein the drop seat sub-frame portion is configured for receiving and securing thereon a drop seat.

CROSS-RELATED APPLICATIONS

This non-provisional application claims priority to and the benefit ofpreviously filed U.S. Provisional Application having Ser. No. 61/271,697and filing date of Jul. 25, 2009 entitled “SUB-FRAM AND COMPONENTCONFIGURATION FOR MOUNTING OF A MOTORCYCLE DROP SEAT” wider 25 U.S.C.§119(e), which is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

The embodiments of the present invention relate to a novel sub-framestructure for a motorcycle and to a novel spatial arrangement ofmotorcycle components within a cavity partially defined by thesub-frame.

SUMMARY OF THE INVENTION

A sub-frame and component configuration for mounting on a motorcycleincludes a body frame structure including a main frame portion; and asub-frame portion, he sub-frame is fixedly secured to the main frameportion and is configured for receiving and securing thereon a drop seatproviding a rider with a seating area that is relatively closer to theground than the seating area of a conventional motorcycle seat.

A method of mounting the sub-frame on a motorcycle is provided andincludes: fixedly securing a drop seat sub-frame portion onto a mainframe portion, wherein the drop seat sub-frame portion is configured forreceiving and securing thereon a drop seat.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a left side elevational view of a motorcycleincluding a conventional body frame structure with a conventional seat.

FIG. 2 illustrates a left side elevational view of a motorcycleincluding a modified body frame structure with a configuration thataccommodates a seat that is lower than a conventional seat in accordancewith an embodiment of the invention.

FIG. 3 illustrates a detailed view of the encircled portion 2′ denotedby a dashed line shown in FIG. 1.

FIG. 4 illustrates a detailed view of the encircled portion 2 denoted bya dashed line shown in FIG. 2 in accordance with an embodiment of theinvention.

FIG. 5 illustrates a left side elevational view of a main frame of amotorcycle not attached to a sub-frame.

FIG. 6 illustrates a left perspective view of a body frame structure inaccordance with an embodiment of the invention.

FIG. 7 a illustrates a right perspective view of a body frame structurein accordance with an embodiment of the invention.

FIG. 7 b illustrates an exploded assembly view of the body framestructure shown in FIG. 7 a.

FIG. 8 a illustrates a top view of a body frame structure of amotorcycle in accordance with an embodiment of the invention.

FIG. 8 b illustrates a detailed view of a sub-frame portion of the bodyframe structure shown in FIG. 8 a in accordance with an embodiment ofthe invention.

FIG. 9 illustrates a right side elevational view of the body structureframe shown in FIG. 8 a in accordance with an embodiment of theinvention.

FIG. 10 illustrates a left side elevational view of the body structureframe shown in FIG. 8 a in accordance with an embodiment of theinvention.

FIG. 11 illustrates a front elevational view of the body structure frameshown in FIG. 8 a in accordance with an embodiment of the invention.

FIG. 12 illustrates a rear elevational view of the body structure frameshown in FIG. 8 a in accordance with an embodiment of the invention.

FIG. 13 a illustrates a left side elevational view of a new sub-frameportion in accordance with an embodiment of the invention.

FIG. 13 a illustrates a right side elevational view of a new sub-frameportion in accordance with an embodiment of the invention.

FIG. 14 illustrates a perspective view of a battery box in accordancewith an embodiment of the invention.

FIG. 15 illustrates a perspective view of an ABS manifold bracket, anABS module, and an ECD module in accordance with an embodiment of theinvention.

FIG. 16 illustrates an assembly view of the components shown in FIGS. 14and 15 in accordance with an embodiment of the invention.

FIG. 17 a illustrates a side elevational view of a fuse box retainer andretainer wheel assembly in accordance with an embodiment of theinvention.

FIG. 17 b illustrates a perspective view of the fuse box retainer andretainer wheel assembly shown in FIG. 17 a.

FIG. 18 illustrates a fuse box retainer assembly including a fuse boxretainer and cover in accordance with an embodiment of the invention.

FIGS. 19-46 illustrate steps involved in detaching a conventional seatsub-frame and then attaching a drop seat sub-frame to a motorcycle bodyframe and in repositioning and securing various components to themotorcycle in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

The present invention generally relates to a sub-frame and componentconfiguration for mounting of a motorcycle drop seat that provides asafe footing for a rider to ride a motorcycle. Like elements arereferred to with like reference numbers throughout. Additionally,reference to “right” and “left” is referenced from a rider on amotorcycle. A conventional motorcycle seat and conventional stock subframe as referenced herein includes seats that are seated on a stock subframe, similar to the stock sub frame 20 b′ shown in FIG. 3, that has anupper tubular or support member having a first end attached to a mainframe and extends across the sub frame along a horizontal plane toterminate at a second end extending to a rear section of a fendersupport frame shown to the rear of FIG. 3.

Referring to the drawings, in particular, FIGS. 1 and 2 illustrate aleft side elevational view of a motorcycle 10, 10′, respectively. FIGS.3 and 4 illustrate a detailed view of the encircled portion 2′ and 2denoted by a dashed line shown in FIGS. 1 and 2 respectively. Theconventional stock sub frame 20 b′ shown in FIG. 3 has an upper tubularor support member having a first end attached to a main frame andextends linearly and substantially coaxially with a longitudinal axis ofa top mounting portion of the main frame where the stock sub frame 20 b′attaches to the main frame 20 a across the sub frame continuously alonga substantially horizontal plane to terminate at a second end, whereinthe second end terminates at a rear section of the sub frame 20 b′proximate to the fender support frame. There is no drop in height of theupper tubular or support member defining a gap or distance between thetop mounting portion of the main frame and the upper tubular or supportmember throughout the length between the first end and the second end ofthe tubular stock sub-frame 20 b′ member.

As seen in FIGS. 1 and 3, a conventional motorcycle seat is 28′ mountedto a conventional sub-frame 20 b′ which is attached to an associatedmain frame portion 20 a to form a body frame structure 20′ shown in moredetail in FIG. 3. Motorcycle 10′ includes a body frame structure 20′, afront fork 14 connected to the body frame 20′, and a front wheel 12supported by a front fork 14. Body frame structure 20′ also supportsmotor 22, transmission. 24, gas tank 26, and a conventional seat 28′ andvarious other elements (for example, a battery, ABS module, ECM module,ignition cables, etc.) which may be necessary or desirable for operationof the motorcycle. A rear wheel 16 is also connected to the body framestructure 20′ via a swing arm frame 18 or other, similar mechanism.

FIGS. 2 and 4 illustrate a motorcycle, designated generally by referencenumeral 10, incorporating a sub-frame structure and associated elementsin accordance with an embodiment of the present invention. Motorcycle 10includes a body frame structure 20, a front fork 14 connected to thebody frame 20, and a front wheel 12 supported by a front fork 14. Bodyframe structure 20 in FIG. 4 supports motor 22, transmission 24, gastank 26, and a “drop seat” 28 and various other elements (for example, abattery, ABS module, ECM module, ignition cables, etc.) which may benecessary or desirable for operation of the motorcycle. A rear wheel 16is also connected to the body frame structure via a swing arm frame 18or other, similar mechanism.

A body frame structure 20 in accordance with embodiments of the presentinvention includes a conventional or stock main frame portion 20 a and aspecially-designed sub-frame portion 20 b in accordance with embodimentsof the present invention. In one embodiment, sub-frame portion 20 b(described in greater detail below) is a separate part and is configuredfor attachment to main frame portion 20 a using any suitable method, forexample, bolts or welds. Alternatively, sub-frame portion 20 b may beformed integrally with main frame portion 20 a. Sub-frame portion 20 bis also configured for receiving and securing thereon a “drop seat” 28,shown in FIG. 1, providing a rider with a seating area that isrelatively closer to the ground than the seating area of a conventionalseat.

Referring to FIGS. 4, 6, 7 a, 7 b, 9-10, 13 a, 13 b, sub-frame portion20 b includes a pair of opposed first portions 25 a, 25 b configured forattachment to main frame portion 20 a at a respective opposing mainframe top mount 17 a, 17 b. In an embodiment of the invention, as shownin more detail in FIG. 4, the first portions 25 a, 25 b each have afirst segment mounting portion 21 a, 21 b that each attaches torespective opposing main frame mounts 17 a, 17 b and are each inlongitudinal alignment with a respective longitudinal axis Lax, Lbx ofeach associated main frame top mounts 17 a, 17 b; and further attach toa respective second segment portion 22 a, 22 b, each having a predefinedlength. La1, Lb1. The second segment portions 22 a, 22 b each form apredefined angle A1 downwardly from each of the longitudinal axes Lax,Lbx of the main frame top mount 17 a, 17 b. A pair of opposed secondportions 24 a, 24 b each having a predefined length La2, Lb2 areconnected to respective second segment portions 22 a, 22 b of theopposed first portions 25 a, 25 b, wherein the second portions 24 a, 24b are each respectively located a predefined distance, D below thelongitudinal axes Lax, Lbx of the mainframe top mounts 17 a, 17 b to arespective point fa, fb on the second portions 24 a, 24 b. In anembodiment of the invention shown in FIG. 4, the distance D is aboutthree inches between the longitudinal axes Lax, Lbx of the main frametop mounts 17 a, 17 b to the respective points fa, fb on the secondportions 24 a, 24 b. However, the distance D may be adjustable based onthe configuration of the first and second portions with respect to themain frame top mounts 17 a, 17 b, in particular, the distance D variesin accordance with the following variables: angle A1 formed between thesecond segment portions 22 a, 22 b and each respective one of thelongitudinal axes Lax, Lbx of the main frame top mount 17 a, 17 b; thepredefined lengths La1, Lb1 of the second segment portions 22 a, 22 b;and the predefined lengths La2, Lb2 of the second portions 24 a, 24 b.

As shown in FIGS. 4, 6, 7 a, 7 b, 9 (right sub-frame), 10 (leftsub-frame); 13 a, 13 b a pair of opposed third portions 26 a, 26 b areconnected to respective ones of the opposed second portions 24 a, 24 band extend upwardly at a predefined angle A2 from each of the opposedsecond portions 24 a, 24 b, respectively. First portion 25 a, secondportion 24 a, and third portion 26 a combine to form a left sub-frameportion 29 (shown in FIGS. 4, 6, 10, and 13 a) of the motorcycle, andfirst portion 25 b, second portion 24 b, and third portion 26 b combineto form a right sub-frame portion 30 (shown in FIGS. 4, 7 a, 9, and 13b) of the motorcycle.

The frame portions comprising the elements of left and right sub-frameportions 29 and 30 may be connected using any suitable method. In oneparticular embodiment, one or more of left and right sub-frame portions29 and 30 is formed from a single bar or piece of tubing which is bentto provide the configuration shown in FIGS. 4, 6, 7 a; 7 b, 8 a, 8 b,9-12, 13 a, 13 b. Alternatively, the constituent elements of one di mareof left and right sub-frame portions 29 and 30 may be welded together orotherwise suitable connected.

FIG. 5 illustrates stock main frame portion 20 a not attached to thesub-frame portion 20 b.

As seen in FIG. 4, the constituent elements of each of left and rightsub-frame portions 29 and 30 are angled with respect to each other so asto define a depression or receptacle 32 suitable for receiving a portionof the motorcycle drop seat therein. In addition, a pair of opposedfourth portions 28 a, 28 b are configured for attachment to main frameportion 20 a as shown in FIGS. 4, 6-7 a, and 7 b at bottom main framemount 19 a, 19 b. As seen in FIGS. 4, 6-7 a, 7 b, 9-10, 13 a, 13 b thirdportions 26 a, 26 b and fourth portions 28 a, 28 b are connected torespective ones of a pair of opposed fifth portions 34 a, 34 b, usingbolts, welds, or any other suitable means. In the embodiment shown inFIGS. 4, 6, 7 a, 7 b, 9-10, 13 a, and 13 b, fifth portions 34 a, 34 bserve as fender braces for the rear fender of the motorcycle.

In a conventional motorcycle, numerous operational components of themotorcycle are positioned within a cavity residing under the motorcycleseat and defined by portions of the motorcycle body frame. In a frameincorporating a drop seat sub-frame in accordance with embodiments ofthe present invention, the cavity defined by the body frame is smallerthan the cavity defined by a body frame using a conventional seat andsub-frame.

As described below, in the embodiments of the present invention, novelhardware components are utilized to enable a novel spatial arrangementof the operational components within the cavity defined by the drop seatsub-frame. This novel spatial arrangement facilitates incorporation ofsub-frame portion 20 b into the motorcycle frame by enabling thecomponents to fit within the smaller cavity defined partially by thedrop seat sub-frame.

As seen in FIGS. 4, 6, 7 a, 7 b, 8 a, 8 b, 9-10, 13 a, 13 b, left andright sub-frame portions 29 and 30, fourth portions 28 a, 28 b, andfifth portions 34 a, 34 b combine to define a cavity 40 in which variousoperational components of the motorcycle are received and secured, in amanner described in greater detail below. A cross-over tube 41 (see FIG.8) extends between opposed fourth portions 28 a and 28 b. Sub-frameportion 20 b provides support and mounting points for the rear fender,shock absorbers, drop seat, tour packs, battery box, and otheraccessories that attach to the rear of the motorcycle. As describedherein, sub-frame portion 20 b is configured for attachment to any of avariety of stock or existing main frame portions. The bars or tubingforming left and right sub-frame portions 29 and 30 may have anysuitable cross-sectional shapes and dimensions and may be formed fromsteel, aluminum, or any other suitable material.

FIGS. 19 a, 19 b, and 20-46 details attachment of a sub-frame 20 b inaccordance with embodiments of the present invention to a conventionalmain frame portion 20 a. Reference to FIGS. 19 a, 19 b, and 20-46 alsodescribes detachment of operational components of the motorcycle from aconventional motorcycle body frame, and the rotation and/orrepositioning and securement of the components within a cavity formed bymain frame portion 20 a and sub-frame portion 20 b, in accordance withembodiments of the present invention.

Turn Signal Module

Referring to the FIGS. 6, 7 a, 7 b, 8 b, and FIGS. 27 and 35, in acomponent spatial arrangement in accordance with one embodiment of thepresent invention, a turn signal module mount 42 is configured forreceiving therein a known turn signal module 43 (shown in FIGS. 27 and35 to enable selective positioning of the turn signal module 43 withincavity 40. In the conventional motorcycle described above, the turnsignal module 43 is mounted in a stock battery box 46′ (shown in FIG.28). In the embodiments described herein, turn signal module mount 42defines an enclosure within which the turn signal module is positionedand secured using any suitable method.

As described in FIG. 27, during installation of sub-frame 20 b andrepositioning of the motorcycle components, the turn signal module 43 isremoved from the stock battery box 46′ that was installed in themotorcycle, and then secured within turn signal module mount 42. Turnsignal module mount 42 is attached to a cross-member of body framestructure 20 using any of a variety of known methods, such as bolts,tie-wraps, or adhesives. In a particular embodiment, turn signal modulemount 42 is attached to cross-over tube 41. When the turn signal module43 is secured in turn signal module mount 42, the module mount 42provides the module with a degree of protection from dirt, oil, andother contaminants. Turn signal module mount 42 may be formed from ametallic material, a polymer material, or any other suitable material orcombination of materials.

Battery Box Assembly

Referring now to the FIGS. 6, 7 a, 7 b, 8 a, 8 b, 11-12, 13 a, 14-16,21, 34, and 36, a battery box assembly 44 includes a battery box 46, anABS manifold 48, an ABS module 50, a battery 45 (shown in FIGS. 21 and36), an ECM module 54, and an ignition coil 91 (shown in FIG. 34) andignition module 90. Battery box 46 is configured to hold a motorcyclebattery and to provide mounting points for ECM module 54, ABS module 50,and the ignition coil 91 and ignition module 9. Battery box 46 includesa substantially rectangular base 46 a and two pairs of opposed walls 46b and 46 c projecting from base 46 a to define an enclosure 46 d. Anangled portion 46 e projects from one of walls 46 c. Battery box 46 isattached to a cross-member of body frame 20 and also to cross-over tube41 using any suitable method, for example bolts, tie-wraps, or adhesiveattachment. In the embodiment shown in the drawings, battery box angledportion 46 e is bolted to cross-over tube 41 to attach the battery boxto sub-frame portion 20 b. In an embodiment of the invention, a portionof battery box 46 (including angled portion 46 e) is configured andpositioned to serve as an extension of the motorcycle rear fender to aidin protecting the internal components of the motorcycle from road dust,spray, oil, and other contaminants. Battery box 46 may be formed from ametallic material, a polymer material, or any other suitable material orcombination of materials.

ABS Assembly

To accommodate installation of the drop seat on a motorcycle whichincludes an ABS braking system, the ABS control module 50 is removedfrom its location in the stock motorcycle and re-positioned withincavity 40. The ABS module is attached to battery box 46. Referring toFIGS. 7 a, 7 b, 15-16, and 43, ABS module 50 is attached to an exteriorof battery box 46 using any suitable method, for example bolts,tie-wraps, or adhesive attachment. The ABS module 50 is a known moduleused for controlling an ABS braking system in the motorcycle. Toaccommodate installation of the drop seat on the motorcycleincorporating a sub-frame 20 b in accordance with embodiments of thepresent invention, the ABS module 50 is also rotated approximately 180degrees relative to its orientation in a conventional body frame, andthen repositioned and secured farther toward the rear of the motorcycle.

An ABS manifold bracket 48 includes openings 48 a extending therethroughto facilitate connection of the brake lines to the ABS module. Referringto FIGS. 7 a, 7 b, 15-16, and 43, ABS manifold bracket 48 is attacheddirectly to the ABS module 50 using any suitable method, for examplebolts, tie-wraps, or adhesive attachment. The ABS manifold bracket 48enables re-routing of the motorcycle brake lines to the new location ofthe ABS module 50 and connection of the motorcycle brake lines to there-located ABS module 50.

To re-position the ABS module 50, the brake lines entering the ABSmodule 50 in the factory motorcycle are removed from the ABS module 50.The ABS module 50 is then removed from the motorcycle frame and attachedto battery box 46 using bolts or another suitable method. The ABSmanifold bracket 48 is attached to the ABS module 50, and the motorcyclebrake lines are attached to the ABS manifold bracket 48, using bolts oranother suitable method. The previously detached brake lines are thenre-connected to the ABS module 50 through openings 49 in the ABSmanifold bracket 48. Both the brake lines and the ABS manifold openings49 are labeled to facilitate connection of each brake line to a properassociated receptacle in the ABS module. For example, in one embodiment,four brake lines are labeled “Fm”, “MF”, “R”, and “MR”, and ABS manifoldopenings directed to associated connection points on the ABS module arealso labeled “Fm”, “MF”, “R”, and “MR”. The end of the brake linelabeled “Fm” is inserted into the ABS manifold opening labeled “Fm” andbolted in place to the ABS manifold. The same procedure is followed forthe other brake lines. In a particular embodiment, the brake lines areconnected to the ABS module 50 and bolted in place to the ABS usingspecially-designed bolts.

ECM Module

FIGS. 7 b, 8 b, 9, 13 b, 15-16, 19, and 42 refer to the configuration,removal and installation of ECM module 54. To accommodate installationof the drop seat on the motorcycle, the ECM module 54 is removed fromits location in the stock motorcycle and re-positioned within cavity 40.In the embodiment shown, ECM module 54 is attached to battery box 46using bolts or another suitable method. The ECM module 54 is a stock orknown electronic control module that was previously installed in thestock motorcycle 10′. In a particular embodiment, the ECM module 54 isbolted to the battery box using specially-designed bolts.

To accommodate installation of the drop seat on the motorcycle, themotorcycle ignition coil 91 is removed from its location in the stockmotorcycle and re-positioned within cavity 40 as shown in FIG. 34. Inthe embodiment shown in FIG. 34, the ignition coil is attached tobattery box 46 using bolts or another suitable method. In a particularembodiment, the ignition coil and ignition module 90 is bolted to thebattery box 46 using specially-designed bolts.

Also, the ignition module 90 originally mounted on the motorcycle isrepositioned and secured to the battery box 46. In a particularembodiment, the ignition module 90 is mounted to the rightmost side ofthe battery box 46, proximate the right side of the motorcycle.

Referring to FIGS. 31-32, 37-38 to accommodate repositioning of thecomponents within the motorcycle frame structure, specially-designedextended length battery cables 66 a, 66 b (shown in FIG. 7 b) areprovided for connecting the battery 45 to the starter 104, electricalcircuits, ground, and the ignition system.

Referring to FIGS. 7 b, 10, and 19 a, to accommodate installation of thedrop seat on the motorcycle, the fuse 67 (shown FIG. 19 a) and fuse boxretainer belt safety wheel assembly 76 built into the motorcycle arerepositioned and incorporated into a fuse box assembly, generallydesignated 70. Fuse box assembly 70 includes a fuse box retainer 64, afuse box retainer mounting bracket 64 d (shown in FIG. 13 a), a fuse boxretainer cover 64 c (shown in FIG. 13 a, 18 b), and the retainer boxsafety wheel assembly 76.

To facilitate relocation of the fuse holder 72, a fuse box retainermounting bracket 64 d (shown in FIG. 13 a) is provided to furnish one ormore mounting points for an associated fuse box retainer 64 in which thefuse is located. The fuse box retainer mounting bracket 64 d is attachedto main frame portion 20 a just below where the first segment mountingportion 21 a of sub-frame 20 b is attached to the main frame portion 20a, on the left side of the motorcycle. The fuse box retainer mountingbracket 64 d is attached to main frame portion 20 a using bolts oranother suitable method.

Fuse box retainer 64 is attached to the fuse box retainer mountingbracket 64 d using bolts or another suitable method. Fuse box retainer64 includes a base 64 a, a series of walls 64 b projecting from the baseto define an enclosure, and a mounting bracket 64 d extending from oneof walls 64 b. The fuse 67 slides into fuse box retainer 64 and is heldin place by a lip formed in the fuse box retainer.

The fuse box retainer 64 is also sized to receive therein a substantialportion of the motorcycle wiring harness connected to the fuses. Fusebox retainer 64 thus provides a relatively compact storage receptaclefor a portion of the wiring harness, thereby freeing additional spacewithin cavity 40 for other components.

A fuse box retainer cover 64 c (shown in FIGS. 13 a, 18, and 40) issecured to fuse box retainer 64 to cover enclosure 64 c, therebyproviding a substantially weather tight protective enclosure for thestock fuse box 72′ residing within the fuse box retainer 64, to aid inpreventing damage to the fuses. The fuse box retainer cover 64 c issecured to fuse box retainer 64 using bolts or another suitable method.

Referring to FIGS. 5, 9, 13 a, 17 a, 17 b, 18, 39-40, a fuse boxretainer safety wheel assembly 60 installed on the production motorcycleis removed from its original location on the motorcycle and is attachedto fuse box retainer 64 on a side of the fuse box retainer 64 oppositethe side to which the fuse box retainer mounting bracket 64 d isattached. The fuse box retainer safety wheel assembly 60 is made up of afuse box safety retainer wheel 80 and associated hardware including abolt 79, a washer 77 and nut 81 for attaching the wheel 80 to the fusebox retainer 64. In one embodiment, the wheel 80 is attached to the fusebox retainer 64 on a side of the fuse box retainer 64 opposite the sidealong which the fuse box retainer mounting 64 is attached to the fusebox retainer mounting bracket 64. Wheel 80 engages an associated drivebelt (not shown).

The original function of fuse box retainer safety wheel assembly 60 isto serve as a belt tensioner for the drive belt. However, asrepositioned in the embodiments of the present invention, assembly 60serves as a belt tensioner and also as a spacing mechanism to aid inpreventing contact between the belt 82 and fuse box retainer assembly70.

Referring to FIG. 7 b, a pair of side covers 88 a, 88 b is provided toenclose cavity 40 and adjacent portions of the motorcycle frame afterinstallation of sub-frame 20 b and installation and repositioning of themotorcycle internal components as described herein. Side covers 88 a, 88b are specially configured for attachment to a body frame 20incorporating sub-frame 20 b and are designed to protect the internalcomponents of the motorcycle from weather and road debris. Side covers88 may be attached to the motorcycle frame using bolts or any othersuitable method.

FIGS. 19-46 details the sequence of steps performed to remove a factorysub-frame from body frame 20, to install the drop seat frame portion 20b, and to install and/or reposition and secure the operationalcomponents of the motorcycle as described above.

In an embodiment of the invention, a conventional sub-frame 20 b′ as isshown in more detail in FIG. 3 is removed from the stock main frameportion 20 a by removing the following stock parts from the motorcycle10 shown in FIG. 1: the conventional seat 28′, which is replaced by thedrop seat 28, shown in FIG. 1; side covers, which are replaced by newside covers 88 a, 88 b; saddlebags, which are reused; a seat strap,which may be reused, front saddlebag mounting brackets, which arereused; and an antenna, which is reused. Additionally, the followingcomponents are removed from the motorcycle 10 before installing thesub-frame portion 20 b to form motorcycle 10′ with the drop seatconfiguration as shown in FIG. 1: a fuse 67 from underneath aconventional fuse box retainer 64′ (shown in FIG. 18), the conventionalfuse cover box retainer 64′ is replaced with a new fuse box retainer 64,an ECM 54 (shown in FIG. 19), which is reused, an ECM tray 55, whichwill not be reused (shown in FIG. 20); a battery 45, which is reused(shown in FIG. 21), saddlebag support bolts 100, which are reused (shownin FIG. 22); bolts 102 that hold the sub-frame 20 b′ to main frame 20 a(shown in FIGS. 23-25). Finally, before installation of the newsub-frame portion 20 b, the conventional sub-frame 20 b′ is removed fromthe motorcycle 10′ as shown in FIG. 26. The following components areremoved or relocated before the new sub-frame 20 b is installed to formmotorcycle 10 shown in FIG. 1: spark plug wires from the ignition coil;the turn signal module 43, which is relocated (shown in FIG. 27); thestock battery box 46′, which will not be reused and which is removedfrom the motorcycle (shown in FIG. 28); the battery cable 66 a′, whichwill not be reused, from the starter 104 (shown in FIG. 29) and from thefuse plug-in; the ground cable 66 b′, which will not be used, from theframe 20 (shown in FIG. 30).

Once the afore-mentioned components are removed, or relocated, thefollowing components are installed or relocated before installing thenew sub-frame 20 b: a new ground/battery cable 66 b, which has a smallwire that attaches to a stud (shown in FIGS. 31-32). Next, the newsub-frame 20 b may be set into place on the motorcycle and connect tothe main frame 20 a by hand-starting the bolts 102 associated with thesub-frame 20 b and then tightening with a suitable wrench. The bolts 102may be color-coded to assure proper assembly. The following componentsare rerouted to fit within the associated new sub-frame components: fusebox wiring 65, the ignition coil 91 are received within a new batterybox 46; the positive battery cable 66 a is rerouted (FIG. 34); the stockturn signal module 43 is installed into a new turn signal module mount42 so that the top of the turn signal module 43 is level with a top ofthe frame 20 b (shown in FIG. 35); the battery 45 within the new batterybox 46 (shown in FIG. 36); the ground cable 66 b is connected to thebattery 45 (shown in FIG. 37); a positive battery cable 66 a isinstalled to a side-post of the battery 45 (shown in FIG. 38); the fuseholder 65 is installed into a new fuse box retainer assembly 64 and ismounted to the sub-frame 20 b (shown in FIG. 39); the fuse box retainercover 64 c is installed (shown in FIG. 40). Additional wiring, includingthe antenna and components including the saddlebag support brackets, andthe fenders may then be reinstalled, wherein the fenders may attach tothe new sub-frame (shown in FIG. 41). Additionally, the ECM module 54(FIG. 42) and optionally the ABS (anti-lock brake system) module 50, fora motorcycle having ABS may be installed in the battery box 44 asdescribed further below. A new drop seat 28 as shown in FIG. 42 may beinstalled and adjusted with a seat bracket for proper fitting.

In general, a method of mounting a sub-frame and component configurationon a motorcycle includes:

fixedly securing a drop seat sub-frame portion onto a main frameportion, wherein the drop seat sub-frame portion is fixedly secured tothe main frame portion and is configured for receiving and securingthereon a drop seat providing a rider with a seating area that isrelatively closer to the ground than the seating area of a conventionalmotorcycle seat and securing a drop seat to the drop seat sub-frameportion.

Initially, a stock sub-frame portion may be removed from the main frameportion.

Additionally, a turn signal module is removed from the stock-frameportion or a stock battery box, a battery is removed from the stockbattery box, and the stock battery box is removed from the motorcycle.Then, the removed turn signal module is mounted to a turn signal modulemount attached to the drop seat sub frame.

The drop seat battery box may attach the drop seat sub-frame, whereinthe drop seat battery box houses a battery and is adapted to receive oneor more of an ABS manifold bracket, an ABS module and an ECM moduletherewithin.

Additionally an angled portion of the battery box may be attached to thecross-over tube, wherein the angled portion is configured and positionedto serve as an extension of the motorcycle rear fender to aid inprotecting the internal components of the motorcycle from contaminants.

An ignition coil and an ignition mounting module may also be mounted tothe drop seat battery box.

In addition, a fuse box assembly including a fuse, a fuse holder, a fusebox retainer, and a fuse box retainer safety wheel assembly may beattached to the drop-seat sub-frame.

It should be understood that the preceding is merely a detaileddescription of various embodiments of this invention and that numerouschanges to the disclosed embodiments can be made in accordance with thedisclosure herein without departing from the spirit or scope of theinvention. The preceding description, therefore, is not meant to limitthe scope of the invention.

1. A sub-frame and component configuration for mounting on a motorcyclecomprising: a body frame structure including a main frame portion; and asub-frame portion, wherein the sub-frame is fixedly secured to the mainframe portion and is configured for receiving and securing thereon adrop seat providing a rider with a seating area that is relativelycloser to the ground than the seating area of a conventional motorcycleseat.
 2. The subframe and component configuration of claim 1, whereinthe sub-frame portion comprises: a pair of opposed first portionsincluding a pair of opposed first segment mount portions configured forattachment to the main frame portion at a respective one of two opposingmain frame top mounts, a pair of opposed second segment portions thatform a first predefined angle downwardly from each of a longitudinalaxis of a respective main frame top mount; a pair of opposed secondportions; and a pair of opposed third portions connected to a respectiveone of the opposed second portions and respectively extend upwardly at apredefined second angle from each of the opposed second portions,wherein the second portions connect one of each respective thirdportions to an associated one of each respective first portions, andwherein each respective opposing first, second, and third portionscombine to form a respective left and right sub-frame portion.
 3. Thesubframe and component configuration of claim 2, wherein the pair ofopposed first segment mount portions each have a first length; whereinthe pair of opposed second portions each have a second length; whereinthe second portions are each respectively located a predefined distanceD below a respective longitudinal axis of the mainframe top mounts to arespective point on an associated one of the second portions; and wherethe distance D is adjusted with the following variables: the first angleA1 formed between the second segment portions and each respective one ofthe longitudinal axes of the main frame top mount; the first lengths ofthe second segment portions and the second lengths of the secondportions.
 4. The subframe and component configuration of claim 2,wherein each of the opposing first, second, and third portions of eachrespective left and right sub-frame portions and are angled with respectto each other so as to define a receptacle suitable for receiving aportion of a motorcycle drop seat therein.
 5. The sub-frame andcomponent configuration of claim 4, wherein a cross-over tube is formedbetween the left and right sub-frame portions and connects the twosub-frame portions.
 6. The subframe and component configuration of claim2, further comprising: a pair of opposed fourth portions configured forattachment to the main frame portion at a respective opposing pair ofbottom main frame mounts; and a pair of opposed fifth portions, whereineach respective opposing third and fourth portions are connected to arespective one of the fifth portions; and
 8. The subframe and componentconfiguration of claim 2, wherein the fifth portions serve as fenderbraces for the rear fender of the motorcycle.
 9. The sub-frame andcomponent configuration of claim 1, further comprising: a battery boxformed between the two sub-frame portions further including: an ECMmodule housed therewithin a fuse box retainer assembly including a fusebox retainer defined by a base and adjacent walls that form an enclosureto enclose a fuse holder, and a fuse box retainer mounting bracket thatmounts the fuse box retainer assembly to a portion of the sub-frame, afuse box retainer safety wheel assembly including a fuse box retainersafety wheel; and a turn-signal module mount.
 10. The sub-frame andcomponent configuration of claim 9, further comprising: a cavity adaptedto house the battery box, fuse box retainer assembly, and theturn-signal mount therewithin.
 11. The sub-frame and componentconfiguration of claim 9, further comprising: an ABS manifold; and anABS module.
 12. The sub-frame and component configuration of claim 11,further comprising: a cavity adapted to house: the battery box, fuse boxretainer assembly, the turn-signal mount, the ABS manifold and the ABSmodule therewithin.
 13. A method of mounting a sub-frame and componentconfiguration on a motorcycle comprising: fixedly securing a drop seatsub-frame portion onto a main frame portion, wherein the drop seatsub-frame portion is configured for receiving and securing thereon adrop seat providing a rider with a seating area that is relativelycloser to the ground than the seating area of a conventional motorcycleseat; and securing a drop seat to the drop seat sub-frame portion. 14.The method of claim 13, further comprising: removing a stock sub-frameportion from the main frame portion before fixedly securing the dropseat sub-frame portion onto the main frame portion.
 15. The method ofclaim 13, further comprising: removing a turn signal module from a stocksub-frame or stock battery box; removing a battery from the stockbattery box; removing the stock battery box from the motorcycle; andsecuring the removed turn signal module to a turn signal module mountattached to the drop seat sub frame.
 16. The method of claim 13, furthercomprising: attaching a drop seat battery box to the cross-over tube ofthe drop seat sub-frame, wherein the drop seat battery box houses abattery and is adapted to receive one or more of an ABS manifoldbracket, an ABS module and an ECM module therewithin.
 17. The method ofclaim 13, further comprising: attaching an angled portion of the dropseat battery box to the cross-over tube, wherein the angled portion isconfigured and positioned to serve as an extension of the motorcyclerear fender to aid in protecting the internal components of themotorcycle from contaminants.
 18. The method of claim 13, furthercomprising: attaching an ignition coil and ignition mounting module tothe drop seat battery box.
 19. The method of claim 13, furthercomprising: attaching a fuse box assembly including a fuse, a fuseholder, a fuse box retainer, and a fuse box retainer safety wheelassembly to the drop-seat sub-frame.